Typical part: orbiting scroll / fixed scroll
The scroll tooth profile is complex, and cutting load may vary along the tool path. The scroll plane and end face also place high demands on flatness, surface quality, and machining consistency. Therefore, rough machining and finish machining require different insert structures and edge strategies.
Machining challenge: Why is it not advisable to use a single insert for all operations?
Rough machining: insufficient stability in stock removal
During rough turning of the scroll teeth and plane, variations in stock allowance, interrupted cutting, or impact cutting may cause edge chipping and inconsistent tool life, which in turn affects tool change frequency, cycle time, and batch consistency.
Finish machining: difficult to balance efficiency and end-face quality
When relying on grinding, the process count and clamping time increase; when ordinary turning is used to replace grinding, it may be difficult to continuously control end-face flatness and stability.
Core logic of the solution: separate roughing from finishing, rather than using one insert for both
Definition of UHD's ductile iron scroll machining solution:The approach separates two independent goals: "high-force, stable stock removal" and "end-face accuracy and surface quality control," with two different CBN insert structures taking on the respective tasks. Rough turning leaves stable, controllable stock and a reliable datum for finish turning, while finish turning focuses on the quality targets of the scroll plane or end face, forming a clear turn-instead-of-grind process path.
Recommended CBN inserts: matched by process and structure
Integral Brazed CBN Insert Series
Applicable process:For rough turning of scroll teeth and the scroll plane. The all-brazed structure prioritizes edge strength and impact resistance, making it suitable for handling stock variation and potential interrupted cutting. Its core function is to remove stock stably and establish a controllable machining foundation for subsequent end-face finish turning.
Full Face CBN Insert series
Applicable process:For finish turning of the scroll plane / end face. Full-face CBN inserts emphasize edge consistency and machining stability, making them suitable for operations with high end-face quality requirements. They can reduce dependence on grinding and support a turn-instead-of-grind process replacement approach.
Applicable conditions and implementation method
- Rough turning of scroll teeth and planeSuitable for mass-production stock removal applications. By prioritizing impact resistance and cutting stability with all-brazed CBN inserts, tool-life variation can be reduced and cycle fluctuations caused by inconsistent tool life can be minimized.
- Finish machining of scroll plane / end faceSuitable for processes focused on flatness, surface quality, and cycle-time optimization. Finish turning with full-face CBN inserts can reduce process transfers and clamping steps, establishing a foundation for replacing grinding with turning.
- Special equipment or non-standard operating conditionsFor production lines with differences in fixture rigidity, stock variation, or continuous/interrupted cutting patterns, the insert structure, geometric parameters, and machining parameters can be adapted accordingly, with application guidance and recommendations for regrinding/refurbishment strategies provided.
Process value for mass production
Stable stock removal
Focus the rough turning objective on cutting stability and stock control, reducing interference from rough machining on the final surface requirements.
Controllable end-face quality
Use finish turning to target end-face quality and flatness requirements, making the quality management path clearer.
Reduced process dependence
Replacing part of the grinding demand with end-face finish turning helps reduce clamping, transfer, and related overall machining costs.
Easier cross-line replication
The modular logic of separating roughing and finishing helps establish a stable process window first, then optimize locally according to equipment differences.
As a supplier of ultrahard cutting tools and custom solutions,Henan UHD Ultrahard Tools Co., Ltd.we can provide CBN insert selection, non-standard structural adaptation, machining parameter guidance, and full lifecycle service support based on the material, machining area, equipment conditions, and quality targets of ductile iron scrolls.